Textured yarn



March 22, 1966 c. M. IRWIN ETAL 3,241,305

TEXTURED YARN Original Filed Nov. 23, 1962 2 Sheets-Sheet l AIR SUPPLY CONTROLLER 5 I5 9 22 G .v

H 2 23 G- I.

INVENTOR. 3 9 E. A. Max/rosy CM 1PM A TORNEY March 22, 1966 c. M. IRWIN ETAL 3,241,305

TEXTURED YARN 26 V I8 26 '8 5 2O 9 IO 9 IO 4 a. l3 l2 l7 7 l5 l5 IS IS F|G.2. F|G.3.

' 'Vt/Vl/L F|G.4. INVENTORS 4 53 :53 [52 [52 E [52 BY FIG.5. A ORNEY United States Patent 3,241,305 TEXTURED YARN Claude M. Irwin and Euell K. McIntosh, Pensacola, Fla, assignors to Monsanto Company, St. Louis, Mo., a corporation of Delaware Original application Nov. 23, 1962, Ser. No. 239,607. Divided and this application .lan. 18, 1965, Ser. No.

r 8 Claims. (Cl. 57-140) This is a division of Serial No. 239,607, filed November 23, 1962.

This invention relates to textured filament yarn produced from cold-drawable' thermoplastic polymers, and more particularly, relates to continuous nylon yarns having different intermittent and variable crimped patterns.

Continuous filament yarn modified in some manner to increase its bulk and stretch properties is known as textured yarn. Textured or bulky yarns provide a softer hand, greater insulation and more subdued luster than non-bulked yarns and are commercially desirable. Continuous filament yarn is rendered bulky by modifying its shape. Some of the different shapes into Which continuous filament yarn is deformed for bulking purposes are crimps, coils, curls and loops.

Crimped textured yarn as applied herein refers to continuous filament yarn to which sinusoidal or corrugated deformation stresses in the form of latent crimps are applied to render the yarn potentially cr-impable and which latent crimps upon subsequent heat treatment fluff, blossom, or emerge into wavy, true or developed crimps.

Continuous uniformly crimped yarn, that is, yarn having substantially the same size of crimps applied along its continuous length, is produced according to known procedure by feeding and compressing the yarn into a stuffer box so as to cause the individual filaments to fold or bend at a sharp angle upon contact with a wall surface.

Continuous uniformly crimped yarn is also produced by delivering the yarn to a heat stretch zone for heating and stretching the yarn, stressing the yarn by passing it between intermeshing denticulated Wheels, and thereafter applying heat to the yarn to develop the stresses in the form of corrugated crimps.

It is often desirable for styling reasons in such end uses as dress goods, draperies, upholstery and the like to produce textured yarns which have intervaled or intermittent crimps applied along its length. The crimped and uncrimped sections of the continuous yarn when in the end product reflect differences of luster as well as variances in bulk thereby odering contrasting end pattern effects.

It is an object of this invention to provide textured yarn having a regular or irregular pattern of intermittent and variable crimps.

A further object is to produce continuous uniformly crimped yarn, continuous variably crimped yarn, intermittent-uniformly crimped yarn having a regular or irregular interval pattern and intermittent-variably crimped yarn having a regular or an irregular interval pattern.

Other objects and advantages of the present invention will become apparent by reference to the detailed description which follows and to the accompanying drawing. In the drawing:

FIGURE 1 is a schematic elevation view illustrating apparatus for producing latently crimped yarn in accordance with the invention;

FIGURE 2 is an elevation view, partly in cross-section, of the components of the draw and crimp assembly of the texturing apparatus in a crimping position;

3,2413 05 Patented Mai. 22, 1966 FIGURE 3 is an elevation view similar to that shown in FIGURE 2 illustrating the draw and crimp assembly in a noncrimping position;

FIGURE 4 is an elevation view showing the novel yarn produced having an intermittent-variable crimped profile applied at regular intervals along its length;

FIGURE 5 is an elevation view showing another novel yarn produced having an intermittent-variable crimped profile applied at irregular intervals along its length; and

FIGURE 6 is a schematic elevation view showing apparatus and method for developing the texture of the latently crimped yarn.

The yarn texturizing apparatus in one preferred form and operation comprises driven feed roll means for feeding a yarn delivered thereto to a rotatable draw and crimp means including a pair of separable denticulated rolls which are operatively driven at a faster peripheral rate of speed than the feed roll means so as to draw the yarn normally laced thereb'etween. The denticulated rolls are adapted to be positioned to a closely spaced intermeshed position to cooperatively apply deformation stresses or latent crimps to the yarn passing therethrough or to an out-of-mesh position to provide an uncrimped section in the yarn by actuator means yieldably connected thereto. The actuator means acts responsively to a control valve means which is connected to a source of air under pressure and to a timing means. The timing means, which is connected to a source of electrical energy, operates the control valve means to alternately connect the actuator means for a preselected period of time to the source of air under pressure for positioning the denticulated rolls of the draw and crimp means to their intermeshed position for crimping the yarn passing therebetween, and then to simultaneously cut off the flow of air to and to vent the air from the actuator means for positioning the denticulated rolls to their out-of-mesh position for discontinuing deformation of the yarn for a preselected period of time. By continuous repetition of the above sequence, the yarn is latently crimped at intermittent intervals along its axis. After being latently crimped, the yarn preferably is taken up by a conventional take-up device. The yarn before or after being taken up can be heat treated under low tension to develop the latent crimps in the yarn.

A controller means is interposed between the control means and the source of air supply to selectively regulate the pressure of air supplied to the actuator means when it is desired to vary the amplitude of the crimps in the crimped sections of the yarn. Regulating the air pressure supplied to the control means between a predetermined range of values determines the adjusted interrneshed position of the denticulated rolls relative to one another and consequently the degree of deformation stress applied to the yarn. By changing the timing sequence of the timing means, the length of the crimped and un crimped sections in the yarn is controlled to provide a regular or an irregular pattern of crimped to uncrimped sections.

The novel method for producing intermittent-variable crimped yarn comprises the steps of providing a source of molecularly orientable synthetic continuous filament yarn made from a thermoplastic polymer and continuously advancing the orientable yarn longitudinally through a heat stretch zone wherein the temperature of the yarn is elevated and the yarn is attenuated a predetermined extent there-by increasing its molecular orientation thereof. Most of the attenuation is localized in the area where the yarn temperature is elevated. Thereafter intermittent and variable latent deformation stresses or crimps are imparted to the yarn at either regular or irregular intervals along its length thereof by passing the yarn between controlled alternately intermeshing and unmeshing peripherally denticulated rolls. The latently c-rirnped yarn is then subjected to heat whereupon the latent crimps develop into truly textured crimps. The textured yarn is thereafter collected on any conventional yarn take-up device.

One type of novel yarn which is produced with the method and apparatus of the invention has repetitive sections of vari-dimensional sinusoidal crimps applied intermittently and at equally distanced intervals along the length thereof, the amplitude of the crimps being variable in the different crimped sections thereof. Another type produced is similar to the one described above but the crimped and uncrimped sections are of unequal length along the longitudinal axis of the yarn.

Referring to FIGURES 1, 2, 3 and 6 of the drawing, the apparatus for producing textured yarn embodying the invention includes a feed roll assembly having a pair of surface engaging rolls 1 and 2 for forwarding a yarn 3 such as nylon, from a packaged source thereof as bobbin 4, to a draw and crimping device 5. One of the rolls, roll 2, is positively driven by suitable power means to a predetermined rate of speed so that the yarn forwarded by rolls 1 and 2 is nipped therebetween. To properly tension and guide the yarn traveling to the feed roll assembly from bobbin 4, the yarn is directed engagingly around a tension guide 6 and thence through a pigtail guide 7.

A snubbing or draw pin 8 provided with heating means and having a smooth contact surface is located intermediate the feed roll assembly and crimping device 5. Draw pin 8 is mounted to be stationary and axially askew with respect to the axes of the feed rolls 1, 2 to prevent .the yarn normally laced therearound to become superimposed. The skewed position of draw pin 8 causes the yarn to travel in a helical turn thereabout. Draw pin 8 is provided with heating means connected to a source of electrical power by suitable leads so that the yarn normally therearound is heated .to a predetermined elevated temperature.

The draw and crimping device consists of a yoke 9 which is pivotally supported at one side thereof about a pin 10 secured to a frame 11. A crimp roll 12, having an axial bore extending therethrough and a spur gear 13, preferably integrally formed therewith at one end thereof, is rotatably mounted as by hearings on a spindle 14 journaled at its ends within yoke 9. Crimp roll 12 has a continuous toothed or denticulated peripheral surface at its end opposite spur gear 13. A second peripherally denticulated crimp roll 15, similar to crimp roll 12, is securely mounted on the end of a driven shaft 16 which is journaled in frame 11 and which is driven by suitable power means. Crimp roll has a spur gear 17 integrally formed at its one end thereof.

Crimp rolls 12, 15 are arranged in close relation with their axes normally being parallel and their respective spur gears 13, 17 being in meshing engagement for constantly driving the crimp rolls 12, 15. When crimp rolls 12, 15 are in parallel alignment .the denticles or teeth on the rolls are constructed to intermesh in closely spaced relation therebetween without actually contacting each other. The denticles on crimp rolls 12, 15 are finer and much more delicate in construction than gear teeth and extend axially and continuously along the outer periphery of each crimp roll.

A stud bolt 18 is threaded transversely through yoke 9 near its pivoted side thereof and can be screwed in and out of yoke 9 upon loosening a lock nut 19 threaded thereon. The adjusted position of stud bolt 18 determines its point of contact with a stop member 20 in frame 11 so as to variably limit the degree of pivotal rocking of crimp roll 12 toward crimp roll 15 to prevent contact and damage of the teeth thereof.

A separator roll 21 is rotatably mounted at one end thereof on frame 11 adjacent to crimp roll 15. The yarn is normally laced in a plurality of wraps about crimp roll 15 and separator roll 21. The axis of separator roll 21 is slightly tilted in relation to the axis of crimp roll 15 to cause the plural wraps of yarn to travel in spaced relation therearound.

Yoke 9 and crimp roll 12 are angularly rocked in one direction away from crimp roll 15 and about pin 11 by a pneumatic cylinder actuator 22 and in the opposite direction toward crimp roll 15 by a resilient spring 23 connected at one end to yoke 9 and at its opposite end to actuator 22. Actuator 22 has a piston 24 sealing'ly reciprocable within a casing 25 secured to frame 11. Piston 24 has a stem 26 extending outwardly therefrom at one side thereof. Stem 26 extends outwardly of casing 25 and into contact with yoke 9. At its side opposite stem 26, piston 24 is subject to air under pressure normally supplied to a chamber 27 defined in casing 25.

Chamber 27 is open to one end of a pipe 28 connected to casing 25. Pipe 28 at its other end is connected to a conventional electric-pneumatic three-way type valve 29 and provides communication between the latter and chamber 27. Valve 29 is connected by leads or wires 30 .to an electrical timing device 31 which is connected to a source of electrical energy. Valve 29 is also connected by a pipe 32 to a reservoir 33 normally supplied with air under pressure for providing communication therebetween. Valve 29 is positionable to an open position for permitting air to pass from reservoir 33 to the pneumatic cylinder actuator 22 via pipes 28 and 32 and to a cut-off position for cutting off the flow of air from reservoir 33 while at the same time venting pipe 28 and chamber 27 of actuator 22.

A pressure gauge 34 is interposed in pipe 33 and a controller 35 is connected to pipe 32. Controller 35, which may be of the balanced valve type, is normally selectively regulated to permit the pressure of air to build-up in pipe 28 and chamber 27 to a desired value, as will herein-after be explained, when valve 29 is in its open position. By controlling the pressure of air supplied to chamber 27 of actuator 22 it is possible under one condition of operation to move piston 24 and there fore stem 26 toward yoke 9 so as to pivot crimp roll 12 closer toward crimp roll 15 against the force of spring 23 and under another condition to permit spring 23 to pull yoke 9 and crimp roll 12 away from crimp roll 15.

A yarn twister device 36 is positioned near the crimp= ing device and serves to twist and take-up the yarn de livered thereto from the draw and crimp assembly 5 via a pigtail guide 37. Yarn twister device 36 includes a rotatable bobbin 38 driven by belt and motor means (not shown), and a reciprocable traverse ring 39 operable concentrically about bobbin 38. A ring traveler 40 is slidably mounted on the reciprocable ring 39 and serves to carry the yarn around the bobbin 38 while the yarn is taken-up. It will be understood that any other suitable form of package building apparatus could be used in place of the yarn twister device 36.

To develop the potential crimpability induced in the yarn by the draw and crimp assembly 5 and to simultaneously set the developed crimp, a heat treating device 41 (FIGURE 6) is provided. Device 41 comprises an endless conveyor belt 42 driven by suitable drive means (not shown) and a heating cabinet 43 having a radiant heat applicator means, such as an array of heating lamps 44. Bobbin 38 packaged with latently crimped yarn is dolfed or removed from twister device 36 and is positioned near the conveyor belt 42. The yarn from bobbin 33 is extended to a traverse guide 45 which lays the yarn from bobbin 38 onto the belt 42 in a zig-zag pattern. The yarn is carried through the cabinet 43 where it is heat conditioned to develop the latent crimps previously applied. The yarn becomes bulked and is carried by belt 42 outwardly from cabinet 43 where it is advanced to another traverse guide 46 that moves the yarn reciprocably across the face of a take-up bobbin 47. Bobbin 47 is surface driven by a driven roll 48. It is to be understood that other apparatus arrangements can be employed for subjecting the yarn to an elevated temperature while under little or no tension.

In operation, the yarn is initially laced as shown in FIGURE 1. The yarn extends from bobbin 4 to the feed rolls 1, 2 after passing around tension guide 6 and through pigtail guide 7. The yarn then passes between feed rolls 1, 2 and is advanced to the crimp rolls 12, 15 after being laced around draw pin 8. Several successive wraps are taken around roll 15 and separator roll 21, and then the yarn further advances to bobbin 38 of yarn twister device 36 after passing through pigtail guide 37 and ring traveler 40 of the twister device 36. Crimp rolls 12, 15 are arranged to be driven at a certain peripheral rate of speed faster than the peripheral speed of feed rolls 1, 2 to stretch the yarn therebetween.

To produce continuous filament yarn having intermittent crimps along its length, timing device 31 is timed to alternately energize and de-energize the three-way valve 29 to permit communication between the pneumatic cylinder actuator 22 and reservoir 33, and to cut off the air supply therefrom while simultaneously venting actuator 22, respectively, in the above alternate sequence according to any predetermined time interval. Meanwhile, controller 35 is positioned to control the pressure of air delivered to chamber 27 of actuator 22 at a value so as to pivot crimp roll 12 against the force of spring 23 into intermeshing position with crimp roll 15 a desired distance to apply deformation stresses in the form of latent crimps in the yarn passing between the rolls. The intermeshing distance between the teeth of rolls 12, 15 is limited by adjustment of stud bolt 18. Screwing stud bolt 18 inward toward stop member 20 in frame 11, as shown in FIGURES 2 and 3, will permit a smaller bite or clearance between the crimp rolls and vice versa.

Assume that valve 29 has been moved to a cut-off position by timing device 31. In this case the flow of air from reservoir 33 is cut off from actuator 22, and chamber 27 of the actuator 22 is vented through valve 29. Upon venting of actuator 22, spring 23 pivotally rocks yoke 9 and crimp roll 12 about pin 19 away from crimp roll 15 to a position where crimp roll 12 does not engage the yarn as is shown in FIGURE 3. Although the crimp rolls 12, 15 are completely out of mesh, it will be noted that spur gears 13, 16 are angularly engaged and therefore crimp roll 15 will be driven so as to continue to forward yarn 3 to bobbin 38. No crimp is applied to the yarn while actuator 22 is vented.

Assume now that timing device 31 moves valve 29 to an open position. Air under pressure from reservoir 33 then is supplied to chamber 27 of actuator 22. In this case, air under pressure in chamber 27 acts on piston 24 and causes the latter to reciprocate for moving stem 26 outwardly of casing 25. Stem 26 then pivotally and angularly rocks yoke 9 and crimp roll 12 to a position where the crimp rolls 12, 15 intermesh as shown in FIG- URE 2. Preferably, the pressure of air should be of such a value so as to rock yoke 9 to a position where stud bolt 18 contacts stop member 20 against the force of spring 23. While the crimp rolls 12, 15 are in their intermeshing position, deformation stresses are applied to the yarn traveling therebetween. The compressive forces are applied to the yarn mostly along the apices of the teeth of rolls 12, 15. The yarn, before being delivered to the crimp rolls 12, 15 is softened as it passes over heated pin 8 and is therefore readily deformed by the teeth of crimp rolls 12, 15. Because the yarn is under tension traveling between the rolls 12, 15, the yarn takes a straight path from apex to apex of the teeth of the rolls 12, 15 such that the material of the yarn is not merely pressed into a corrugated form corresponding to the space between the teeth but has compression tension stresses applied thereto along portions contacting the teeth of the rolls. These stresses are here referred to as latent crimps.

The crimps in the yarn will be vari-dimensional, that is, the convolutions of the crimped yarn will extend radially in many directions when viewed in cross section, according to the number of wraps taken about separator roll 21 and crimp roll 12. It will be noted that where more than one wrap is taken the yarn passes between the crimp rolls 12, 15 a number of times. Due to slight twisting of the yarn between wraps, the yarn does not pass through the rolls 12, 15 in the same position every time and thus the crimps are applied in different dimensions radially of the yarn axis.

It Will be noted that as crimp roll 12 rocks angular-1y away from crimp roll 15 from a condition where the crimp rolls 12, 15 are in parallel axial alignment, the latent crimps applied nearest the spur gears 13, 16, as viewed in FIGURE 2, will be of slightly greater magnitude than those applied adjacent the outer ends of the crimp rolls opposite the spur gears.

By repeated actuation of valve 29 alternately from open to cut-off position by timing device 31, a latently intermittently crimped yarn is produced. The crimps will be of uniform amplitude or size so long as the air is maintained at a predetermined constant pressure by controller 35.

Continuous intermittent-variably crimped yarn having latent crimps of non-uniform amplitude formed along its linear length as shown in FIGURE 4 is produced by varying the pressure of air supplied to chamber 27 of actuator 22 between a range of values necessary for causing intermeshing of crimp rolls 12, 15 against the force of spring 23.

The length of the latent crimped sections relative to the uncrimped sections on the yarn 3 is controlled by setting timing device 31 according to whether a regular .pattern is desired, that is where the length of the crimped and uncrimped sections are equal, or an irregular pattern is desired, where the length of the crimped sections relative to the uncrimped sections are different. FIG- URES 4 and 5 show two ditferent types of yarns which can be produced with the described method and apparatus. FIGURE 4 illustrates a yarn having crimped portions 50, 51 and uncrimped 49 portions wherein the crimped 50, 51 and uncrimped 49 portions are of the same length and where the crimps in portion 50 are of a different amplitude than those of portion 51. FIG- URE 5 illustrates a yarn having crimped portions 53, 54 and uncrimped portions 52 wherein the crimped portions 53, 54 are of a different length than the uncrimped portions 52, and where the crimps in portions 54 are not only of a different amplitude than those in portions 53, but are variable within the portions.

The potentially or latently crimped yarn is then takenup on bobbin 38 and thereafter the yarn from bobbin 38 is layed on conveyor belt 42 and carried into cabinet 43 of heat treating device 41. The application of heat to the latently crimped yarn causes the deformed sections to fluff or bulk. The bulked yarn is carried out of the cabinet 43 and then for a distance along the belt to permit it to cool before it is taken-up on bobbin 46.

It will be understood that if desired, the apparatus could be used to produce continuously uniformly crimped yarn without any straight uncrimped sections by setting the timing device 31 to maintain the valve 29 constantly in an open position so as to keep crimp rolls 12, 15 constantly intermeshing. The crimp could be varied along the length of the yarn by varying the pressure of the air delivered to chamber 27 of actuator 22 as previously explained. The controlled apparatus and method for producing textured yarn embodying the invention is flexible in operation so as to provide many different selective types of patterned yarns. The apparatus is not costly and is simple in structure and operation and the method is not complicated.

Variations and modifications of the present invention are contemplated within the scope and limitations of the claims.

We claim:

1. A continuous novelty yarn made from a thermoplastic polymer, said yarn comprising fluffy corrugated crimped portions at intermittent intervals between uncrimped portions along its length thereof, some crimped portions having a diiferent crimp amplitude pattern than other crimped portions.

2. A continuous novelty yarn as claimed in claim 1 wherein the crimped and uncrimped portions are of equal length.

3. A continuous novelty yarn as claimed in claim 1 wherein the crimped and uncrimped portions are of unequal length.

4. The continuous novelty yarn of claim 1 made of nylon.

5. A continuous novelty yarn made from a thermoplastic polymer, said yarn comprising fiufiy corrugated crimped portions spaced at irregular intermittent intervals between uncrimped portions along its length thereof, some crimped portions having uniform crimps of difierent amplitude in relation to other uniformly crimped portions and some crimped portions having a variable crimp 8 amplitude pattern different than other variably crimped portions.

6. A continuous novelty yarn as claimed in claim 5 wherein the crimped portions and the uncrimped portions are equally spaced.

7. A continuous novelty yarn made from a thermoplastic polymer, said yarn comprising regular and irregular lengths of crimped and uncrimped segments and uniform and non-uniform crimp amplitude patterns within the crimped segments at various points along the length of the yarn.

8. A continuous novelty yarn made from a thermoplastic polymer, said yarn comprising crimped portions between uncrimped portions along its length thereof, said crimped portions being crimped in many dilferent crimp amplitude patterns.

References Cited by the Examiner UNITED STATES PATENTS 3,034,196 5/1962 Bohmfalk 28-1 3,136,111 6/1964 Pittman 57140 3,137,911 6/1964 Bromley 28-1 3,140,525 7/1964 Lamb 28--1 MERVIN STEIN, Primary Examiner.

DONALD W. PARKER, Examiner. 

1. A CONTINUOUS NOVELTY YARN MADE FROM A THERMOPLASTIC POLYMER, SAID YARN COMPRISING FLUFFY CORRUGATED CRIMPED PORTIONS AT INTERMITTENT INTERVALS BETWEEN CRIMPED CRIMPED PORTIONS ALONG ITS LENGTH THEREOF, SOME CRIMPED PORTIONS HAVING A DIFFERENT CRIMP AMPLITUDE PATTERN THAN OTHER CRIMPED PORTIONS. 